Gas turbine engine bifurcation located fan variable area nozzle

ABSTRACT

A turbofan gas turbine engine includes a core engine within a core nacelle, a fan nacelle at least partially surrounding the core nacelle to define a bypass flow path and a variable fan nozzle exit area for bypass flow, and a pylon variable area flow system which operates to effect the bypass flow. A method of operating a turbofan gas turbine engine is also disclosed.

REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 15/889,304, filed Feb. 6, 2018, which a continuation of U.S. patent application Ser. No. 13/343,964, filed Jan. 5, 2012, which is a continuation in part of U.S. patent application Ser. No. 12/441,546, filed Mar. 17, 2009.

BACKGROUND OF THE INVENTION

The present invention relates to a gas turbine engine, and more particularly to a turbofan engine having a bifurcation which effectively varies a fan nozzle exit area by adjusting a variable area flow system within the bifurcation to selectively vary the bypass area through which bypass flow may pass.

Conventional gas turbine engines include a fan section and a core engine with the fan section having a larger diameter than that of the core engine. The fan section and the core engine are disposed in series along a longitudinal axis and are enclosed in a nacelle. An annular stream of primary airflow passes through a radially inner portion of the fan section and through the core engine to generate primary thrust.

Combustion gases are discharged from the core engine through a primary airflow path and are exhausted through a core exhaust nozzle. An annular fan flow path, disposed radially outwardly of the primary airflow path, passes through a radial outer portion between a fan nacelle and a core nacelle and is discharged through an annular fan exhaust nozzle defined at least partially by the fan nacelle and the core nacelle to generate fan thrust. A majority of propulsion thrust is provided by the pressurized fan air discharged through the fan exhaust nozzle, the remaining thrust provided from the combustion gases discharged through the core exhaust nozzle.

The fan nozzles of conventional gas turbine engines have a fixed geometry. The fixed geometry fan nozzles are a compromise suitable for take-off and landing conditions as well as for cruise conditions. Some gas turbine engines have implemented fan variable area nozzles. The fan variable area nozzle provide a smaller fan exit nozzle diameter during cruise conditions and a larger fan exit nozzle diameter during take-off and landing conditions. Existing fan variable area nozzles typically utilize relatively complex mechanisms that increase overall engine weight to the extent that the increased fuel efficiency typically associated with the use of a fan variable area nozzle may be negated.

SUMMARY OF THE INVENTION

A gas turbine engine according to an exemplary aspect of the present disclosure may include a core engine defined about an axis, a gear system driven by the core engine, the gear system defines a gear reduction ratio of greater than or equal to about 2.3, a fan driven by the gear system about the axis to generate a bypass flow, and a variable area flow system which operates to effect the bypass flow.

In a further non-limiting embodiment of any of the foregoing gas turbine engine embodiments, the variable area flow system may include an annular fan variable area nozzle (FVAN).

In a further non-limiting embodiment of any of the foregoing gas turbine engine embodiments, the gas turbine engine may include a gear system driven by the core engine to drive the fan. The gear system may define a gear reduction ratio of greater than or equal to about 2.5.

In a further non-limiting embodiment of any of the foregoing gas turbine engine embodiments, the gas turbine engine may include a gear system driven by the core engine to drive the fan. The gear system may define a gear reduction ratio of greater than or equal to 2.5.

In a further non-limiting embodiment of any of the foregoing gas turbine engine embodiments, the core engine may include a low pressure turbine which defines a pressure ratio that is greater than about five (5).

In a further non-limiting embodiment of any of the foregoing gas turbine engine embodiments, the core engine may include a low pressure turbine which defines a pressure ratio that is greater than five (5).

In a further non-limiting embodiment of any of the foregoing gas turbine engine embodiments, the bypass flow may define a bypass ratio greater than about six (6).

In a further non-limiting embodiment of any of the foregoing gas turbine engine embodiments, the bypass flow may define a bypass ratio greater than about ten (10).

In a further non-limiting embodiment of any of the foregoing gas turbine engine embodiments, the bypass flow may define a bypass ratio greater than ten (10).

In a further non-limiting embodiment of any of the foregoing gas turbine engine embodiments, the variable area flow system may operate to change a pressure ratio of the bypass flow.

In a further non-limiting embodiment of any of the foregoing gas turbine engine embodiments, the variable area flow system may operate to vary an area of a fan nozzle exit area for the bypass flow.

In a further non-limiting embodiment of any of the foregoing gas turbine engine embodiments, the fan may be defined for a predefined flight condition. Additionally or alternatively, the predefined flight condition may be about 0.8 MACH and about 35,000 feet. Additionally or alternatively, the predefined flight condition may be 0.8 MACH and 35,000 feet.

In a further non-limiting embodiment of any of the foregoing gas turbine engine embodiments, the fan may include fan blades designed at a particular fixed stagger angle related to the flight condition.

In a further non-limiting embodiment of any of the foregoing gas turbine engine embodiments, the variable area flow system may operate to adjust the bypass flow such that an angle of attack of the fan blades are maintained close to a design incidence at flight conditions other than the predefined flight condition.

A gas turbine engine according to another exemplary aspect of the present disclosure may include a core engine defined about an axis. The core engine may include a low pressure turbine which defines a pressure ratio that is greater than about five (5), a fan driven by the core engine about the axis to generate a bypass flow, and a variable area flow system which operates to effect the bypass flow.

In a further non-limiting embodiment of any of the foregoing gas turbine engine embodiments, the variable area flow system may include an annular fan variable area nozzle (FVAN).

In a further non-limiting embodiment of any of the foregoing gas turbine engine embodiments, the core engine may include a low pressure turbine which defines a pressure ratio that is greater than five (5).

In a further non-limiting embodiment of any of the foregoing gas turbine engine embodiments, the gas turbine engine may include a gear system driven by the core engine to drive the fan. The gear system may define a gear reduction ratio of greater than or equal to about 2.5.

In a further non-limiting embodiment of any of the foregoing gas turbine engine embodiments, the bypass flow may define a bypass ratio greater than about six (6). Additionally or alternatively, the bypass flow may define a bypass ratio greater than about ten (10). Additionally or alternative, the bypass flow may define a bypass ratio greater than ten (10).

In a further non-limiting embodiment of any of the foregoing gas turbine engine embodiments, the variable area flow system may operate to change a pressure ratio of the bypass flow. Additionally or alternatively, the variable area flow system may operate to vary an area of a fan nozzle exit area for the bypass flow.

In a further non-limiting embodiment of any of the foregoing gas turbine engine embodiments, the fan may be defined for a predefined flight condition. Additionally or alternatively, the flight condition may be about 0.8 MACH and about 35,000 feet.

In a further non-limiting embodiment of any of the foregoing gas turbine engine embodiments, the fan may include fan blades designed at a particular fixed stagger angle related to the predefined flight condition.

In a further non-limiting embodiment of any of the foregoing gas turbine engine embodiments, the variable area flow system may operate to adjust the bypass flow such that an angle of attack of the fan blades are maintained close to a design incidence at flight conditions other than the predefined flight condition.

BRIEF DESCRIPTION OF THE DRAWINGS

The various features and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the currently preferred embodiment. The drawings that accompany the detailed description can be briefly described as follows:

FIG. 1 is a general schematic partial fragmentary view of an exemplary gas turbine engine embodiment for use with the present invention; and

FIG. 2 is a sectional view through an engine pylon of the engine of FIG. 1 at line 2-2 to illustrate a variable area flow system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 illustrates a general partial fragmentary schematic view of a gas turbofan engine 10 suspended from an engine pylon P within an engine nacelle assembly N as is typical of an aircraft designed for subsonic operation.

The turbofan engine 10 includes a core engine within a core nacelle 12 that houses a low spool 14 and high spool 24. The low spool 14 includes a low pressure compressor 16 and low pressure turbine 18. The low spool 14 drives a fan section 20 connected to the low spool 14 through a gear train 22. The high spool 24 includes a high pressure compressor 26 and high pressure turbine 28. A combustor 30 is arranged between the high pressure compressor 26 and high pressure turbine 28. The low and high spools 14, 24 rotate about an engine axis of rotation A.

The engine 10 is preferably a high-bypass geared turbofan aircraft engine. In one disclosed, non-limiting embodiment, the engine 10 bypass ratio is greater than about six (6) to ten (10), the gear train 22 is an epicyclic gear train such as a planetary gear system or other gear system with a gear reduction ratio of greater than about 2.3 and the low pressure turbine 18 has a pressure ratio that is greater than about 5. Preferably, the engine 10 bypass ratio is greater than ten (10), the fan diameter is significantly larger than that of the low pressure compressor 16, and the low pressure turbine 18 has a pressure ratio that is greater than 5. The gear train 22 is preferably an epicyclic gear train such as a planetary gear system or other gear system with a gear reduction ratio of greater than 2.5. It should be understood, however, that the above parameters are only exemplary of various preferred geared turbofan engines and that the present invention is likewise applicable to other gas turbine engines.

Airflow enters a fan nacelle 34 which at least partially surrounds the core nacelle 12. The fan section 20 communicates airflow into the core nacelle 12 to power the low pressure compressor 16 and the high pressure compressor 26. Core airflow compressed by the low pressure compressor 16 and the high pressure compressor 26 is mixed with the fuel in the combustor 30 where is ignited, and burned. The resultant high pressure combustor products are expanded through the high pressure turbine 28 and low pressure turbine 18. The turbines 28, 18 are rotationally coupled to the compressors 26, 16 respectively to drive the compressors 26, 16 in response to the expansion of the combustor product. The low pressure turbine 18 also drives the fan section 20 through the gear train 22. A core engine exhaust E exits the core nacelle 12 through a core nozzle 43 defined between the core nacelle 12 and a tail cone 32.

The core nacelle 12 is supported within the fan nacelle 34 by a pylon structure often generically referred to as an upper bifurcation 36U and lower bifurcation 36L, however, other types of pylons and supports at various radial locations may likewise be usable with the present invention.

A bypass flow path 40 is defined between the core nacelle 12 and the fan nacelle 34. The engine 10 generates a high bypass flow arrangement with a bypass ratio in which approximately 80 percent of the airflow entering the fan nacelle 34 becomes bypass flow B. The bypass flow B communicates through the generally annular (circumferentially broken only by the bifurcations 36U, 36L) bypass flow path 40 and is discharged from the engine 10 through an annular fan variable area nozzle (FVAN) 42 which defines a variable fan nozzle exit area 44 between the fan nacelle 34 and the core nacelle 12. The upper bifurcation 36U and the lower bifurcation 36L, although aerodynamically optimized (best seen in FIG. 2), occupies some portion of the volume between the core nacelle 12 and the fan nacelle 34.

Thrust is a function of density, velocity, and area. One or more of these parameters can be manipulated to vary the amount and direction of thrust provided by the bypass flow B. The upper bifurcation 36U preferably includes a pylon variable area flow system 50 having a passage 56 defined between a pylon intake 52 and a pylon exhaust 54 to selectively vary the FVAN 42 area through which bypass flow B may pass. Preferably, both the pylon intake 52 and the pylon exhaust 54 are variable and controlled in response to a controller 58. It should be understood that although the upper bifurcation 36U is illustrated in the disclosed embodiment as having the pylon variable area flow passage 50, the lower bifurcation as well as other pylon structures may likewise include such variable area flow systems.

Referring to FIG. 2, the pylon variable area flow system 50 changes the pressure ratio of the bypass flow B. That is, the nozzle exit area 44 is effectively varied in area by opening and closing the additional flow area of the pylon variable area flow system 50 to vary the bypass flow B. It should be understood that various actuators 64, 66 in communication with the controller 58 may be utilized to operate the pylon intake 52 and the pylon exhaust 54 in response to predetermined flight conditions. It should be understood that either of the pylon intake 52 and the pylon exhaust 54 may be fixed but it is preferred that both are adjustable in response to the controller 58 to control the flow area through the flow passage 56.

The flow passage 56 is defined around a component duct 55 within the upper bifurcation 36U which provides a communication path for wiring harnesses, fluid flow conduits and other components to the core nacelle 12 from, for example, the aircraft wing. It should be understood that various flow passage 56 paths will likewise be usable with the present invention.

The pylon intake 52 preferably includes an adjustable intake such as a louver system 60 with empirically-designed turning vanes which most preferably have a variation of height to minimize the “shadowing” effect created by each upstream louver relative the next downstream louver.

The pylon exhaust 54 preferably includes a variable nozzle 59. The variable nozzle 59 may include doors, flaps, sleeves or other movable structure which control the volume of additional fan bypass flow B+ through the FVAN 42.

The pylon variable area flow system 50 changes the physical area through which the bypass flow B may pass. A significant amount of thrust is provided by the bypass flow B due to the high bypass ratio. The fan section 20 of the engine 10 is preferably designed for a particular flight condition—typically cruise at about 0.8 MACH and about 35,000 feet. It should be understood that other arrangements as well as essentially infinite intermediate positions are likewise usable with the present invention.

In operation, the pylon variable area flow system 50 communicates with the controller 58 to effectively vary the area of the fan nozzle exit area 44 through independent or coordinated operation of the pylon intake 52 and the pylon exhaust 54. Other control systems including an engine controller, a flight control computer or the like may also be usable with the present invention. As the fan blades of fan section 20 are efficiently designed at a particular fixed stagger angle for the cruise condition, the pylon variable area flow system 50 is operated to vary the area of the fan nozzle exit area 44 to adjust fan bypass air flow such that the angle of attack or incidence of the fan blades are maintained close to the design incidence at other flight conditions, such as landing and takeoff as well as to meet other operational parameters such as noise level. Preferably, the pylon variable area flow system 50 is closed to define a nominal cruise position fan nozzle exit area 44 and is opened for other flight conditions. The pylon variable area flow system 50 preferably provides an approximately 20% (twenty percent) effective area change in the fan nozzle exit area 44.

The foregoing description is exemplary rather than defined by the limitations within. Many modifications and variations of the present invention are possible in light of the above teachings. The preferred embodiments of this invention have been disclosed, however, one of ordinary skill in the art would recognize that certain modifications would come within the scope of this invention. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. For that reason the following claims should be studied to determine the true scope and content of this invention. 

What is claimed is:
 1. A turbofan gas turbine engine comprising: a fan including a plurality of fan blades; a gear train; a core engine within a core nacelle, the core engine defined along an engine axis, wherein the core engine includes a first compressor, a second compressor, a first turbine driven by the second compressor, and a fan drive turbine that drives the fan through the gear train; a fan nacelle at least partially surrounding the core nacelle to define a bypass flow path and a variable fan nozzle exit area for bypass flow; at least one bifurcation extending between the fan nacelle and the core nacelle in a radial direction and extending between a leading edge and a trailing edge in an axial direction with respect to the engine axis; a pylon variable area flow system which operates to effect the bypass flow, wherein the pylon variable area flow system includes an adjustable pylon intake, an internal flow passage, and an adjustable pylon exhaust, wherein the adjustable pylon intake includes a louvered system having a plurality of turning vanes adjacent the leading edge, the adjustable pylon exhaust is adjacent the trailing edge, the pylon exhaust is axially forward of a trailing edge of the fan nacelle with respect to the engine axis, and the internal flow passage is defined within the at least one bifurcation between the pylon intake and the pylon exhaust; and a controller coupled to a plurality of actuators that operate the pylon intake and the pylon exhaust in response to the controller to cause the pylon variable area flow system to selectively vary the variable fan nozzle exit area.
 2. The turbofan gas turbine engine as recited in claim 1, wherein the internal flow passage extends between the pylon intake and the pylon exhaust such that bypass flow in the bypass flow path enters the pylon intake, then flows through the internal flow passage, and then exits back into the bypass flow path downstream of the pylon intake.
 3. The turbofan gas turbine engine as recited in claim 2, wherein the at least one bifurcation includes a plurality of bifurcations distributed in the bypass flow path.
 4. The turbofan gas turbine engine as recited in claim 3, wherein the controller operates the pylon intake and the pylon exhaust to selectively vary the fan nozzle exit area in response to a flight condition.
 5. The turbofan gas turbine engine as recited in claim 4, wherein the gear train is an epicyclic gear train.
 6. The turbofan gas turbine engine as recited in claim 5, wherein each of the first compressor, the second compressor, the first turbine and the fan drive turbine includes a plurality of stages, and wherein the fan drive turbine includes a greater number of stages than the first turbine.
 7. The turbofan gas turbine engine as recited in claim 6, wherein the fan blades have a fixed stagger angle.
 8. The turbofan gas turbine engine as recited in claim 6, wherein the pylon variable area flow system operates to change a pressure ratio of the bypass flow in response to the controller.
 9. The turbofan gas turbine engine as recited in claim 8, wherein the first compressor includes a greater number of stages than the fan drive turbine.
 10. The turbofan gas turbine engine as recited in claim 8, wherein the fan drive turbine is a three stage turbine.
 11. The turbofan gas turbine engine as recited in claim 8, wherein the fan is configured for a predefined flight condition, and the fan blades are designed at a particular fixed stagger angle related to the predefined flight condition.
 12. The turbofan gas turbine engine as recited in claim 11, wherein the predefined flight condition is 0.8 MACH and 35,000 feet.
 13. The turbofan gas turbine engine as recited in claim 11, wherein the fan drive turbine drives both the first compressor and an input of the gear train.
 14. The turbofan gas turbine engine as recited in claim 13, wherein the pylon intake is established along a sidewall of the respective bifurcation at a position that is spaced apart from the leading edge.
 15. The turbofan gas turbine engine as recited in claim 14, further comprising an annular fan variable area nozzle located at the trailing edge of the fan nacelle which defines the fan nozzle exit area.
 16. The turbofan gas turbine engine as recited in claim 15, wherein the pylon exhaust includes a variable nozzle having a moveable flap.
 17. The turbofan gas turbine engine as recited in claim 16, wherein the predefined flight condition is 0.8 MACH and 35,000 feet.
 18. The turbofan gas turbine engine as recited in claim 17, wherein the plurality of turning vanes have a variation of height.
 19. The turbofan gas turbine engine as recited in claim 18, wherein the plurality of turning vanes are pivotable into the bypass flow path.
 20. A method of operating a turbofan gas turbine engine comprising the steps of: driving a fan connected to a first spool through a gear train, wherein the fan includes a plurality of fan blades, the first spool includes a first compressor and a fan drive turbine, a fan nacelle at least partially surrounds a core nacelle to define a bypass flow path and a variable fan nozzle exit area for bypass flow, the core nacelle houses the first spool and a second spool, the second spool includes a first turbine that drives a second compressor, and at least one bifurcation extends between the fan nacelle and the core nacelle in a radial direction and extends between a leading edge and a trailing edge in an axial direction with respect to an engine axis to support the core nacelle within the fan nacelle; varying a variable area flow system in communication with an internal flow passage through the at least one bifurcation to change a volume of the bypass flow through the at least one bifurcation and control the bypass flow through the variable fan nozzle exit area in response to a flight condition, wherein the variable area flow system is movable toward an open position to increase bypass flow through the variable fan nozzle exit area and toward a closed position to decrease bypass flow through the variable fan nozzle exit area; and wherein the variable area flow system includes a variable pylon intake and a variable pylon exhaust both established along the at least one bifurcation, the internal flow passage extends between the pylon intake and the pylon exhaust, and the pylon intake includes a plurality of turning vanes moveable in response to an actuator.
 21. The method as recited in claim 20, wherein the step of varying the variable area flow system includes communicating the bypass flow from the bypass flow path into the pylon intake, then communicating the bypass flow through the internal flow passage, and then ejecting the bypass flow back into the bypass flow path downstream of the pylon intake.
 22. The method as recited in claim 21, wherein the step of varying the variable area flow system includes pivoting the plurality of turning vanes into the bypass flow path to establish the open position.
 23. The method as recited in claim 21, wherein the at least one bifurcation includes a plurality of bifurcations.
 24. The method as recited in claim 23, wherein the step of varying the variable area flow system includes moving the variable area flow system toward the closed position in response to a cruise flight condition.
 25. The method as recited in claim 24, wherein the step of varying the variable area flow system includes moving the variable area flow system toward the open position in response to a non-cruise flight condition.
 26. The method as recited in claim 25, wherein the fan is configured for a predefined flight condition, the fan blades are designed at a particular fixed stagger angle related to the predefined flight condition, and the predefined flight condition is 0.8 MACH and 35,000 feet.
 27. The method as recited in claim 26, wherein the step of varying the variable area flow system occurs such that an angle of attack of the fan blades is maintained close to a design incidence at flight conditions other than the predefined flight condition.
 28. The method as recited in claim 27, wherein the gear train is an epicyclic gear train, wherein each of the first compressor, the second compressor, the first turbine and the fan drive turbine includes a plurality of stages, and wherein the fan drive turbine includes a greater number of stages than the first turbine.
 29. The method as recited in claim 28, wherein the plurality of turning vanes have a variation of height, the pylon exhaust includes a variable nozzle having a moveable flap, and the step of varying the variable area flow system includes pivoting the flap into the bypass flow path to establish the open position.
 30. The method as recited in claim 29, wherein the step of varying the variable area flow system includes pivoting the plurality of turning vanes into the bypass flow path to establish the open position. 